Ribbed force sensor

ABSTRACT

In one embodiment, a force sensor apparatus is provided including a tube portion having a plurality of radial ribs and a strain gauge positioned over each of the plurality of radial ribs, a proximal end of the tube portion that operably couples to a shaft of a surgical instrument that operably couples to a manipulator arm of a robotic surgical system, and a distal end of the tube portion that proximally couples to a wrist joint coupled to an end effector.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PATENTS

This application is a continuation of U.S. patent application Ser. No.13/932,128 (filed Jul. 1, 2013), which is a continuation of U.S. patentapplication Ser. No. 11/958,772 (filed Dec. 18, 2007), each of which isincorporated by reference herein in its entirety for all purposes.

This application is a continuation of U.S. application Ser. No.13/932,128, filed Jul. 1, 2013, which is a continuation of U.S.application Ser. No. 11/958,772, filed Dec. 18, 2007 now U.S. Pat. No.8,496,647, the full disclosure of which are incorporated by referenceherein for all purposes. This application is related to U.S. ProvisionalApplication No. 60/755,108 filed Dec. 30, 2005, U.S. ProvisionalApplication 60/755,157 filed Dec. 30, 2005, U.S. application Ser. No.11/553,303 filed Oct. 26, 2006, U.S. patent application Ser. No.11/537,241 filed Sep. 29, 2006, U.S. patent application Ser. No.11/093,372 filed Mar. 30, 2005, and U.S. Pat. Nos. 6,936,042, 6,902,560,6,879,880, 6,866,671, 6,817,974, 6,783,524, 6,676,684, 6,371,952,6,331,181, and 5,807,377, the full disclosures of which are incorporatedby reference herein for all purposes.

TECHNICAL FIELD

The present invention relates generally to surgical robot systems and,more particularly, to an improved system, apparatus, and method forsensing forces applied to a surgical instrument.

BACKGROUND

In robotically-assisted surgery, the surgeon typically operates a mastercontroller to control the motion of surgical instruments at the surgicalsite from a location that may be remote from the patient (e.g., acrossthe operating room, in a different room or a completely differentbuilding from the patient). The master controller usually includes oneor more hand input devices, such as handheld wrist gimbals, joysticks,exoskeletal gloves, handpieces, or the like, which are operativelycoupled to the surgical instruments through a controller with servomotors for articulating the instruments' position and orientation at thesurgical site. The servo motors are typically part of anelectromechanical device or surgical manipulator arm (“the slave”) thatincludes a plurality of joints, linkages, etc., that are connectedtogether to support and control the surgical instruments that have beenintroduced directly into an open surgical site or through trocar sleeves(cannulas) inserted through incisions into a body cavity, such as thepatient's abdomen. There are available a variety of surgicalinstruments, such as tissue graspers, needle drivers, electrosurgicalcautery probes, etc., to perform various functions for the surgeon,e.g., retracting tissue, holding or driving a needle, suturing, graspinga blood vessel, dissecting, cauterizing, coagulating tissue, etc. Asurgeon may employ a large number of different surgicalinstruments/tools during a procedure.

This new surgical method through remote manipulation has created manynew challenges. One such challenge is providing the surgeon with theability to accurately “feel” the tissue that is being manipulated by thesurgical instrument via the robotic manipulator. The surgeon must relyon visual indications of the forces applied by the instruments orsutures. It is desirable to sense the forces and torques applied to thetip of the instrument, such as an end effector (e.g., jaws, grasper,blades, etc.) of robotic minimally invasive surgical instruments, inorder to feed the forces and torques back to the surgeon user throughthe system hand controls or by other means, such as visual display,vibrations, or audible tone. One device for this purpose from thelaboratory of G. Hirzinger at DLR Institute of Robotics and Mechatronicsis described in “Review of Fixtures for Low-Invasiveness Surgery” by F.Cepolina and R. C. Michelini, Int'l Journal of Medical Robotics andComputer Assisted Surgery, Vol. 1, Issue 1, page 58, the contents ofwhich are incorporated by reference herein for all purposes. However,that design disadvantageously places a force sensor distal to (oroutboard of) the wrist joints, thus requiring wires or optic fibers tobe routed through the flexing wrist joint and also requiring the yaw andgrip axes to be on separate pivot axes.

Another problem has been fitting and positioning the necessary wires,rods, or tubes for mechanical actuation of end effectors in as small aspace as possible because relatively small instruments are typicallydesirable for performing surgery.

What is needed, therefore, are improved telerobotic systems and methodsfor remotely controlling surgical instruments at a surgical site on apatient. In particular, these systems and methods should be configuredto provide accurate feedback of forces and torques to the surgeon toimprove user awareness and control of the instruments.

SUMMARY

The present invention provides an apparatus, system, and method forimproving force and torque feedback to and sensing by a surgeonperforming a robotic surgery. In one embodiment, a force sensor includesa tube portion that includes a plurality of radial ribs and a straingauge positioned over each of the plurality of radial ribs. A proximalpart of the tube portion is coupled to a shaft of a surgical instrumentthat may be operably coupled to a manipulator arm of a robotic surgicalsystem. A distal part of the tube portion is coupled to a wrist jointcoupled to an end effector. The couplings may be direct or indirect withan intermediate mechanical component between the coupled parts.

Groups of strain gauges are positioned on or near a distal end of aninstrument shaft proximal to (i.e., inboard of) a moveable wrist of arobotic surgical instrument via an apparatus that senses forces andtorques at the distal tip of the instrument without errors due tochanges in the configuration of the tip (such as with a moveable wrist)or steady state temperature variations.

Advantageously, the present invention improves the sensing and feedbackof forces and/or torques to the surgeon and substantially eliminates theproblem of passing delicate wires, or optic fibers through the flexiblewrist joint of the instrument. A force sensor apparatus may bemanufactured, tested, and calibrated as a separate modular component andbrought together with other components in the conventional instrumentassembly process. The force sensor apparatus may also be manufactured asan integrated part of the instrument. In addition, it is possible tochoose a material for the sensor structural member different from thematerial of the instrument shaft whose design considerations maycompromise the mechanical properties required for the sensor.

The scope of the invention is defined by the claims, which areincorporated into this section by reference. A more completeunderstanding of embodiments of the present invention will be affordedto those skilled in the art, as well as a realization of additionaladvantages thereof, by a consideration of the following detaileddescription of one or more embodiments. Reference will be made to theappended sheets of drawings that will first be described briefly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. IA is a perspective view of a robotic surgical system in accordancewith an embodiment of the present invention.

FIG. 1B is a perspective view of a robotic surgical arm cart system ofthe robotic surgical system in FIG. 1A in accordance with an embodimentof the present invention.

FIG. 1C is a front perspective view of a master console of the roboticsurgical system in FIG. 1A in accordance with an embodiment of thepresent invention.

FIG. 2 is a perspective view of a surgical instrument including a forcesensor apparatus operably coupled proximal (or inboard) to a wrist jointin accordance with an embodiment of the present invention.

FIG. 3A is a perspective view of a force sensor apparatus in accordancewith an embodiment of the present invention.

FIG. 3B illustrates the force sensor of FIG. 3A operably coupled to ashaft and end portion of a surgical instrument in accordance with anembodiment of the present invention.

FIG. 3C illustrates the force sensor of FIG. 3A with a protective coverover a portion of the force sensor in accordance with an embodiment ofthe present invention.

FIG. 4A is a perspective view of an inner tube of a force sensorapparatus in accordance with another embodiment of the presentinvention.

FIG. 4B is a partial cross-sectional view of an outer tube/cover overthe inner tube of FIG. 4A of the force sensor apparatus in accordancewith an embodiment of the present invention.

FIG. 4C shows intervening material between the inner and outer tubes ofFIG. 4B of the force sensor apparatus and wires or optic fibers operablycoupled to the force sensor apparatus in accordance with an embodimentof the present invention.

FIG. 4D shows a partial cross-sectional view of the force sensorapparatus operably coupled proximal to (or inboard of) a wrist joint ofa surgical instrument in accordance with an embodiment of the presentinvention.

FIG. SA is a perspective view of a force sensor apparatus in accordancewith yet another embodiment of the present invention.

FIG. 5B illustrates an enlarged perspective view of a section of theforce sensor apparatus of FIG. 5A.

FIG. 5C illustrates a cross-sectional view of the force sensor apparatusof FIG. 5A along line 5C-5C, and FIG. 5C1 illustrates a magnifiedsection labeled 5C1 in FIG. 5C.

FIG. 5D illustrates a cross-sectional view of the force sensor apparatusof FIG. 5A along line 5D-5D.

FIG. 5E illustrates a strain relief for strain gauge wires or opticfibers in accordance with an embodiment of the present invention.

FIGS. 6A and 6B illustrate perspective views of another force sensorapparatus and an enlarged section of the force sensor apparatus inaccordance with another embodiment of the present invention.

FIG. 6C illustrates an end view of the force sensor apparatus of FIGS.6A and 6B including radial ribs positioned in non-uniform angles, andFIG. 6C1 illustrates a magnified section labeled 6C1 in FIG. 6C, inaccordance with another embodiment of the present invention.

FIGS. 7A and 7B illustrate a perspective view and an end view of anotherforce sensor apparatus including radial ribs positioned in non-uniformangles and apertures on the tube surface, and FIG. 7B1 illustrates amagnified section labeled 7B1 in FIG. 7B, in accordance with anotherembodiment of the present invention.

FIG. 8 illustrates an end view of another force sensor apparatusincluding three radial ribs in accordance with another embodiment of thepresent invention.

FIGS. 9A and 9B illustrate perspective views of another force sensorapparatus and an enlarged section of the force sensor apparatus,respectively, in accordance with another embodiment of the presentinvention.

FIG. 9C illustrates an end view of the force sensor apparatus of FIGS.9A and 9B including radial ribs positioned in non-uniform angles and acentral through passage in accordance with another embodiment of thepresent invention.

Embodiments of the present invention and their advantages are bestunderstood by referring to the detailed description that follows. Itshould be appreciated that like reference numerals are used to identifylike elements illustrated in one or more of the figures. It should alsobe appreciated that the figures may not be necessarily drawn to scale.

DETAILED DESCRIPTION

The present invention provides a multi-component system, apparatus, andmethod for sensing forces applied to tissue while performingrobotically-assisted surgical procedures on a patient, particularlyincluding open surgical procedures, neurosurgical procedures, andminimally invasive procedures, such as laparoscopy, arthroscopy,thoracoscopy, and the like. The apparatus and method of the presentinvention are particularly useful as part of a telerobotic surgicalsystem that allows the surgeon to manipulate the surgical instrumentsthrough a servomechanism from a remote location from the patient. Tothat end, the manipulator apparatus or slave of the present inventionwill usually be driven by a kinematically-equivalent master having sixor more degrees of freedom (e.g., 3 degrees of freedom for position and3 degrees of freedom for orientation) to form a telepresence system withforce reflection or other scalar force magnitude display. A descriptionof a suitable slave-master system can be found in U.S. Pat. No.6,574,355, the complete disclosure of which is incorporated herein byreference for all purposes.

Referring to the drawings in detail, wherein like numerals indicate likeelements, a robotic surgical system 10 is illustrated according to anembodiment of the present invention. As shown in FIGS. 1A through 1C,robotic system 10 generally includes one or more surgical manipulatorassemblies 51 mounted to or near an operating table O and a mastercontrol assembly located at a surgeon's console 90 for allowing thesurgeon S to view the surgical site and to control the manipulatorassemblies 51. The system 10 will also include one or more viewing scopeassemblies and a plurality of surgical instrument assemblies 54 adaptedfor being removably coupled to the manipulator assemblies 51 (discussedin more detail below). Robotic system 10 includes at least twomanipulator assemblies 51 and preferably at least three manipulatorassemblies 51. The exact number of manipulator assemblies 51 will dependon the surgical procedure and the space constraints within the operatingroom among other factors. As discussed in detail below, one of theassemblies 51 will typically operate a viewing scope assembly (e.g., inendoscopic procedures) for viewing the surgical site, while the othermanipulator assemblies 51 operate surgical instruments 54 for performingvarious procedures on the patient P.

The control assembly may be located at a surgeon's console 90 which isusually located in the same room as operating table O so that thesurgeon may speak to his/her assistant(s) and directly monitor theoperating procedure. However, it should be understood that the surgeon Scan be located in a different room or a completely different buildingfrom the patient P. The master control assembly generally includes asupport, a monitor for displaying an image of the surgical site to thesurgeon S, and one or more master(s) for controlling manipulatorassemblies 51. Master(s) may include a variety of input devices, such ashand-held wrist gimbals, joysticks, gloves, trigger-guns, hand-operatedcontrollers, voice recognition devices, or the like. Preferably,master(s) will be provided with the same degrees of freedom as theassociated surgical instrument assemblies 54 to provide the surgeon withtelepresence, the perception that the surgeon is immediately adjacent toand immersed in the surgical site, and intuitiveness, the perceptionthat the master(s) are integral with the instruments 54 so that thesurgeon has a strong sense of directly and intuitively controllinginstruments 54 as if they are part of or held in his/her hands.Position, force, and tactile feedback sensors (not shown) may also beemployed on instrument assemblies 54 to transmit position, force, andtactile sensations from the surgical instrument back to the surgeon'shands, ears, or eyes as he/she operates the telerobotic system. Onesuitable system and method for providing telepresence to the operator isdescribed in U.S. Pat. No. 6,574,355, which has previously beenincorporated herein by reference.

The monitor 94 will be suitably coupled to the viewing scope assemblysuch that an image of the surgical site is provided adjacent thesurgeon's hands on surgeon console. Preferably, monitor 94 will displayan image on a display that is oriented so that the surgeon feels that heor she is actually looking directly down onto the operating site. Tothat end, an image of the surgical instruments 54 appears to be locatedsubstantially where the operator's hands are located even though theobservation points (i.e., the endoscope or viewing camera) may not befrom the point of view of the image. In addition, the real-time image ispreferably transformed into a stereo image such that the operator canmanipulate the end effector and the hand control as if viewing theworkspace in substantially true presence. By true presence, it is meantthat the presentation of an image is a true stereo image simulating theviewpoint of an operator that is physically manipulating the surgicalinstruments 54. Thus, a controller (not shown) transforms thecoordinates of the surgical instruments 54 to a perceived position sothat the stereo image is the image that one would see if the camera orendoscope were located directly behind the surgical instruments 54. Asuitable coordinate transformation system for providing this virtualimage is described in U.S. Pat. No. 5,631,973, the complete disclosureof which is incorporated herein by reference for all purposes.

A servo control is provided for transferring the mechanical motion ofmasters to manipulator assemblies 51. The servo control may be separatefrom, or integral with, manipulator assemblies 51. The servo controlwill usually provide force and torque feedback from the surgicalinstruments 54 to the hand-operated masters. In addition, the servocontrol may include a safety monitoring controller (not shown) to safelyhalt system operation, or at least inhibit all robot motion, in responseto recognized undesirable conditions (e.g., exertion of excessive forceon the patient, mismatched encoder readings, etc.). The servo controlpreferably has a servo bandwidth with a 3 dB cut off frequency of atleast 10 Hz so that the system can quickly and accurately respond to therapid hand motions used by the surgeon and yet to filter out undesirablesurgeon hand tremors. To operate effectively with this system,manipulator assemblies 51 have a relatively low inertia, and the drivemotors have relatively low ratio gear or pulley couplings. Any suitableconventional or specialized servo control may be used in the practice ofthe present invention, with those incorporating force and torquefeedback being particularly preferred for telepresence operation of thesystem.

Referring to FIG. 2, a perspective view is shown of a surgicalinstrument 54 including a force sensor apparatus 100 operably coupled toa distal end of a rigid shaft 110 and proximal to a wrist joint 121 inaccordance with an embodiment of the present invention. An end portion120, such as a surgical end effector, is coupled to force sensorapparatus 100 via the wrist joint 121. A housing 150 is operably coupledto a proximal end of the rigid shaft 110 and includes an interface 152which mechanically and electrically couples instrument 54 to themanipulator 51.

Referring now to FIGS. 3A-3C in conjunction with FIGS. 1A-1C and 2, animproved apparatus, system, and method for sensing and feedback offorces and/or torques to the surgeon will be described in accordancewith an embodiment of the present invention. FIG. 3A shows a perspectiveview of force sensor apparatus 100 including in one embodiment a tube102 including a number (e.g., 3, 4, 6, or 8) of strain gauges 104 (e.g.,104 a and 104 b) mounted to a surface of tube 102 and oriented axially(parallel to the lengthwise axis z of the tube). FIG. 3B shows the forcesensor apparatus 100 of FIG. 3A operably coupled to a shaft 110 and endportion 120 of a surgical instrument in accordance with an embodiment ofthe present invention. FIG. 3C shows a cross-section view of forcesensor apparatus 100 including a cover or sleeve 113 over tube 102.

In accordance with an embodiment of the present invention, force sensorapparatus 100 is a separately manufacturable module or part adapted forincorporation as part of the shaft 110 of surgical instrument 54 at aprescribed distance from the tip where there may be an articulated wristwith specialized jaws, cutting devices, or other end portion 120. In oneexample, tube 102 may be made of a sufficiently strong material and maybe spool shaped, including end portions 102 b, 102 c with a depressedportion 102 a therebetween that is smaller in diameter than end portions102 b, 102 c. Strain gauges 104 may be mounted on the surface ofdepressed portion 102 a. Proximal tube portion 102 c operably couples tothe shaft 110 of surgical instrument 54 and distal tube portion 102 boperably couples to a wrist joint 121. In one example, the diameter ofthe completed force sensor apparatus matches the diameter of theinstrument shaft, thus allowing the entire assembly of the instrument(including the coupled force sensor apparatus) to pass through a cannulaor a seal without added friction or snagging.

Force sensor apparatus 100 includes a through passage 109 for endportion actuation cables or rods. End features 108 of end portion 102 binsure secure mounting and angular alignment to the main instrumentshaft and wrist/jaw/other end portion sub-assembly of the instrument.Wire leads or optic fibers 116 (e.g., shielded twisted pairs, coax, orfiber) from the strain gauges 104 may be inlaid into grooves 112 inproximal tube portion 102 c of tube 102 and matching grooves in theshaft 110 of the surgical instrument 54. The wire leads or optic fibers116 may then be embedded in an adhesive bonding or potting compound suchas epoxy.

In one embodiment, as illustrated in FIG. 3C, cover 113 is positionedover and encapsulates the mounted strain gauges 104 and other circuitelements on the surface of the tube 102, thereby providing mechanicalprotection of the sensors. In one example, cover 113 is a mechanicallyprotective woven sleeve potted on depressed portion 102 a and iscomprised of a woven resin impregnated fiberglass or metal braidelectrical shielding.

As disclosed in U.S. patent application Ser. No. 11/537,241, filed Sep.29, 2006, the contents of which have been previously incorporated byreference, strain gauges 104 may be spaced in a ring at intervals aroundthe circumference of the tube 102 (e.g., 3 gauges at 120 degrees, 4gauges at 90 degrees, or 4 gauges at 70 degrees and 110 degrees). Thesignals from the sensors are combined arithmetically in various sums anddifferences to obtain measures of three perpendicular forces (e.g.,F.sub.x, F.sub.y, and F.sub.z) exerted upon the instrument tip and thetorques about the two axes perpendicular to the shaft axis (i.e., axes xand y). In accordance with the present invention, the measurement of theforces is made independent of the orientation and effective lever armlength of an articulated wrist mechanism at the distal end of theinstrument when two axially separated sets or rings of gauges areutilized. Forces exerted against end portion 120 are detected by theforce sensing elements via an interrogator, which may be operablycoupled to the servo control or to a processor for notifying the surgeonof these forces (e.g., via master(s) or a display). It is understoodthat by adding a second ring of similarly oriented gauges (e.g., twosets of 3 gauges or two sets of 4 gauges) at a different axial positionon the tube, additional applied torque information (e.g., T.sub.x andT.sub.y) may be obtained, and dependence of the force data on instrumentwrist length, orientation, and resulting jaw distance may be eliminated.

In one example, various strain gauges may be used, including but notlimited to conventional foil type resistance gauges, semiconductorgauges, optic fiber type gauges using Bragg grating or Fabry-Perottechnology, or others, such as strain sensing surface acoustic wave(SAW) devices. Optic fiber Bragg grating (FBG) gauges may beadvantageous in that two sensing elements may be located along one fiberat a known separation, thereby only requiring the provision of fourfibers along the instrument shaft.

Both fiber technologies require an interrogator unit that decodes theoptically encoded strain information into electrical signals compatiblewith the computer control hardware or display means of the roboticsurgical system. A processor may then be used to calculate forcesaccording to the signals from the strain gauges/sensors.

Additionally, there may be co-mounted unstrained gauges or Poissonstrained gauges oriented in the circumferential direction adjacent toeach axial gauge and incorporated in the bridge completion circuits toeliminate temperature effects. The strain gauge bridge circuits arecompleted in a manner to give the best signal for bending loads due tothe lateral forces (F.sub.x and F.sub.y) exerted on the instrument tipjaws.

For resistive foil or semiconductor strain gauges, active componentssuch as bare die op-amps and passive components such as secondaryresistors or capacitors may be attached adjacent to the strain gaugesconnected by bond wires or thick film circuit traces in the manner ofhybrid circuits to amplify, filter, and/or modulate the gauge outputsignals to reject noise sources. Such components are not needed forfiber optic gauges.

Surgical instrument 54 to which force sensor apparatus 100 couples mayinclude a circumferentially coiled insulated flex circuit style serviceloop of parallel conductive traces at the proximal end of the instrumentshaft 110 permitting the substantially free rotation of the instrumentshaft while conducting the input gauge excitation power and output gaugesignals to stationary housing 150 of the instrument 54.

Housing 150 operably interfaces with a robotic manipulator arm 51, inone embodiment via a sterile adaptor interface 152. Applicable housings,sterile adaptor interfaces, and manipulator arms are disclosed in U.S.patent application Ser. No. 11/314,040 filed on Dec. 20, 2005, and U.S.application Ser. No. 11/613,800 filed on Dec. 20, 2006, the fulldisclosures of which are incorporated by reference herein for allpurposes. Examples of applicable shafts, end portions, housings, sterileadaptors, and manipulator arms are manufactured by Intuitive Surgical,Inc. of Sunnyvale, Calif.

In a preferred configuration, end portion 120 has a range of motion thatincludes pitch and yaw motion about the x- and y-axes and rotation aboutthe z-axis (as shown in FIG. 3A). These motions as well as actuation ofan end effector are provided via cables and/or rods running throughshaft 110 and into housing 150 that transfer motion from the manipulatorarm 51. Embodiments of drive assemblies, arms, forearm assemblies,adaptors, and other applicable parts are described for example in U.S.Pat. Nos. 6,331,181, 6,491.701, and 6,770,081, the full disclosures ofwhich are incorporated herein by reference for all purposes.

It is noted that various surgical instruments may be improved inaccordance with the present invention, including but not limited totools with and without end effectors, such as jaws, scissors, graspers,needle holders, micro-dissectors, staple appliers, tackers, suctionirrigation tools, clip appliers, cutting blades, irrigators, catheters,and suction orifices. Alternatively, the surgical instrument maycomprise an electrosurgical probe for ablating, resecting, cutting orcoagulating tissue. Such surgical instruments are available fromIntuitive Surgical, Inc. of Sunnyvale, Calif.

For the methods and apparatus mentioned above, it may be advantageous touse a calibration process in which combinations of forces and torquesare applied to the instrument tip serially, simultaneously, or incombinations while correction factors and offsets are determined. Thecorrection factors and offsets may then be applied to the theoreticalequations for combining the gauge outputs to obtain F.sub.x, F.sub.y,F.sub.z, T.sub.x, and T.sub.y. Such a calibration process may be doneeither by directly calculating the correction factors and offsets or bya learning system such as a neural network embedded in the calibrationfixture or in the instrument itself. In any calibration method, thecalibration data may be programmed into an integrated circuit embeddedin the instrument so that the surgical system using the individualinstrument can correctly identify and apply its correction factors andoffsets while the instrument is in use.

Advantageously, force sensor apparatus 100 of the present invention isadaptable to the size and shape constraints of various robotic surgicalinstruments and is suitable for a variety of instruments. Accordingly,end portions 102 b, 102 c may be formed into various applicable shapesand sizes. Furthermore, force sensor apparatus 100 may be manufactured,tested, and calibrated as a separate modular component and broughttogether with other components in the conventional instrument assemblyprocess. Also, the sensor may be a slip-on module with suitableelectrical contacts that mate with contacts on the instrument shaftpermitting a higher value sensor to be used with lower cost instrumentsof limited cycle life. In addition, the sensor structural member 102 maybe comprised of an advantageous material, which may be a differentmaterial than the instrument shaft 110 whose design considerations maycompromise the properties required for the sensor.

Referring now to FIGS. 4A through 4D, a force sensor apparatus 200 isillustrated in accordance with another embodiment of the presentinvention. The descriptions of substantially similar parts or elementsas those described above with respect to FIGS. 3A-3C are applicable inthis embodiment with respect to FIGS. 4A-4D, although redundantdescriptions will be omitted.

FIG. 4A is a perspective view of an inner tube 218 of force sensorapparatus 200 in accordance with an embodiment of the present invention.Inner tube 218 includes a proximal raised end portion 218 b and adepressed portion 218 a smaller in diameter than raised end portion 218b. Strain gauges, as described above with respect to FIGS. 3A-3C, may bemounted on the surface of depressed portion 218 a. Raised end portion218 b may include grooves 212 for routing of wire leads or optic fibersfrom strain gauges 204.

FIG. 4B is a partial cross-sectional view of an outer tube 214 over theinner tube 218. In one example, outer tube 214 of force sensor apparatus200 is a concentric tubular structural member made of sufficientlystrong materials that can encapsulate the strain gauges and otherelectronics within an annular gap between the inner and outer tubes 218and 214. In one embodiment, the concentric tubes are joined rigidly atthe proximal end adjacent proximal portion 218 b while a narrow annulargap between the distal ends near a distal portion is filled with anelastomeric material 215 that prevents the high and varying axial forcesof the wrist and jaw actuator cable or rods from being transmittedthrough the inner tube carrying the strain gauges. It is noted that thepartially isolated tube carrying the gauges may be either the outer orthe inner tube. The non-isolated tube of the pair may carry the entireaxial cable load. Preferably, the gauges may be placed on the interiortube to isolate the gauges from the environment. In such an embodiment,the outer tube 214 carries the axial cable forces and also permits theouter tube to provide mechanical protection and potentially act aselectromagnetic interference (EMI) shielding to the gauges 204 on theinner tube 218.

FIG. 4C highlights elastomeric material 215 between the inner tube 218and outer tube 214 of the force sensor apparatus 200, and wires or opticfibers 216 operably coupled to gauges 204. FIG. 4D is a partialcross-sectional view of the force sensor apparatus 200 operably coupledproximal to a wrist joint 221 of a surgical instrument in accordancewith an embodiment of the present invention. Leads 216 (e.g., shieldedtwisted pairs, coax, or optic fiber) from the strain gauges 204 may beinlaid into grooves 212 in proximal tube portion 218 b of tube 218 andmatching grooves in the shaft 210 of a surgical instrument. The leads216 may then be embedded in an adhesive potting compound such as anepoxy.

In one example, if an outer sensor carrying tube is mounted stationaryat the rear mechanism housing, the wire routing may be simplified by notrequiring a rotating joint service loop.

Advantageously, the relative shear and compressive properties ofelastomers enable this design concept. A suitable elastomer 215 with alow shear modulus permits the relative compression and extension of thecable load carrying tube with respect to the sensor carrying tube (whichis connected rigidly at only one end of the tubes as mentioned above).Thus, cable loads and load changes do not affect the sensors. On theother hand, an elastomer confined between two relatively rigid surfaceswhere the gap between the surfaces is small compared to the extent ofthe surfaces behaves as a nearly incompressible rigid connection in thedirection normal to the confining surfaces, in this case the radialdirection of the combined annular tube structure. This causes bendingmoments carried in the axially loaded tube to be transmitted to andshared by the sensor tube. Thus, the sensor tube can advantageouslydetect the bending moments due to lateral loads on the instrument wristand jaws without significant interference or “noise” from the highervarying axial cable loads carried by the other tube. Advantageously, thedecoupling of the load carrying members in an endoscopic surgicalinstrument force sensor enables the separation of undesired jaw actuatortendon forces from desired lateral jaw load induced bending moments onthe force sensor.

Alternatively, the desired effect of axially de-constraining the sensorcarrying tube from the cable load carrying tube at one end may beobtained by inserting an annular ring of a more rigid low frictionmaterial in the annular gap between the unconnected ends of the tubesmachined for a very close fit, thereby permitting the relative axialmotion but transmitting the lateral motion associated with bendingmoments due to the lateral tip forces. Another alternative is to makethe tubes with a very close fit and apply a low friction coating to oneor both surfaces at the distal end. However, these alternatives maycreate a small deadband in sensor response depending on how close a fitmay be reliably obtained. The expansion thermal coefficients of theinner and outer tubes must also be matched or the required close fit maybind when heated or cooled.

It should also be understood that the same decoupling effect achievedwith concentric tubes as described above may potentially be achievedwith alternating axial finger-like members half (or some number) ofwhich carry the axial cable loads while the alternating (or remaining)ones carry the bending loads. Again, these members may be rigidlyconnected at the proximal end while they are decoupled in the axialdirection at the distal end.

Referring now to FIGS. 5A-5E, views of a surgical instrument includinganother force sensor apparatus 300 is illustrated in accordance with yetanother embodiment of the present invention. An end portion 320, such asa surgical end effector, is coupled to force sensor apparatus 300 via awrist joint 321. A housing 150 (FIG. 5E) is operably coupled to aproximal end of a rigid shaft 310, the housing 150 further including aninterface 152 which mechanically and electrically couples the instrumentto the manipulator. FIG. 5B is an enlarged perspective view of anaperture and rib section of the force sensor apparatus of FIG. 5A. FIGS.5C and 5D are cross-sectional views of the force sensor apparatus ofFIG. 5A along lines 5C-5C and 5D-5D, respectively, and FIG. 5C1illustrates a magnified section labeled 5C1 in FIG. 5C. FIG. 5Eillustrates an example proximal portion of the surgical instrumentincluding the housing and operably coupling of the instrument to aninterrogator 334 and processor 340. The descriptions of substantiallysimilar parts or elements as those described above with respect to FIGS.1-4 are applicable in this embodiment with respect to FIGS. 5A-5E,although redundant descriptions may be omitted.

Returning to FIG. 5A, force sensor apparatus 300 includes a generallyannular tube 306 operably coupled to a distal end of rigid shaft 310 andproximal to wrist joint 321 in accordance with an embodiment of thepresent invention. In one embodiment, tube 306 includes a number ofrectangular-shaped apertures 301 cut from tube 306 and a plurality ofradial ribs 302 forming through passages 308 for passage of actuationcables, wires, tubes, rods, and/or flushing fluids. Ribs 302 run alongand radiate from the z-axis centerline of tube 306, and a number (e.g.,3, 4, 6, or 8) of strain gauges 304 are oriented parallel to thelengthwise z-axis of the tube and mounted to an outer rib surface 302 a.The strain gauges may be inlaid into grooves or a depressed area 317 onthe outer rib surface 302 a in one example.

In the embodiment illustrated in FIGS. 5A-5D, force sensor apparatus 300includes two sets of four apertures 301 cut from the wall of tube 306 atseparate axial locations along tube 306. Each of the ribs 302 areseparated by 90 degrees measured about the z-axis centerline of tube306, which forms a cruciform cross-sectional view of the ribs 302, asshown in FIGS. 5C and 5D. Ribs 302 form four through passages 308 forpassage of actuation cables, wires, tubes, and/or rods. Furthermore,ribs 302 may extend along the entire length of tube 306 thereby forminginternal through passages along the entire length of tube 306, or ribs302 may extend along a portion(s) of the length of tube 306, therebyforming internal through passages along a portion or portions of thelength of tube 306.

Force sensor apparatus 300 is capable of sensing bending moments appliedto its distal end due to lateral forces applied to the wrist joint orits specialized end portion. Advantageously, apertures 301 and ribs 302provide for regions of controlled stress and strain when subjected tobending moments, which may be measured by fiber optic strain gauges 304embedded in grooves along an outer surface of the ribs and sensor bodyparallel to the lengthwise z-axis of tube 306. Through passages 308permit cables, wires, tubes, or rigid tendons to pass through the sensorapparatus body to actuate the distal wrist joint(s) and/or control theend portion.

In one example, tube 306 and ribs 302 may be made of a sufficientlystrong but elastic material to allow sensing of stress and strainwithout mechanical failure. Tube 306 and ribs 302 are further comprisedof material with a sufficiently low modulus of elasticity to give asufficient strain signal under an applied load, a sufficiently highstrain at yield to give adequate safety margin above the maximum designload, and a sufficiently high thermal diffusivity to promote rapidthermal equilibrium (therefore reducing thermal disturbances to sensoroutput signals) when subject to localized or asymmetric thermaldisturbances from tissue contact or endoscope illumination. Inparticular, the plurality of radial ribs 302 may be comprised of a highthermal diffusivity material, such as an aluminum alloy (e.g., 6061-T6aluminum) or a copper alloy (e.g., GlidCop® AL-60) to reduce thetemperature difference between opposing gauges under transient thermaldisturbances while providing a direct thermal pathway between opposinggauges.

In one example, tube 306 may be comprised of metal alloys, treatedmetals, or plated metals, such as of aluminum, copper, or silver, whichallow for adequate strain, mechanical failure safety margin, and highthermal diffusivity. In a further example, 6061-T6 aluminum, which is analuminum alloy that is heat treated and aged, GlidCop® AL-60, which iscopper that is dispersion strengthened with ultrafine particles ofaluminum oxide, or a dispersion strengthened silver, may be used to formtube 306 and ribs 302.

Advantageously, the present invention allows for a low bending moment ofinertia to increase a strain signal to noise signal ratio consistentwith a materials choice and rib design meeting the need for high thermaldiffusivity and a direct thermal path between opposing strain gaugeswhile also providing passage for actuation cables, wires, tubes, and/orrods.

Wire leads or optic fibers 316 (e.g., shielded twisted pairs, coax, orfiber) coupled to the strain gauges 304 may be inlaid into grooves 317on tube 306, the outer rib surface 302 a, and matching grooves 319 inshaft 310 of the surgical instrument. The wire leads or optic fibers 316may then be embedded in an adhesive potting compound such as epoxy.

As disclosed in U.S. patent application Ser. No. 11/537,241, filed Sep.29, 2006, the contents of which have been previously incorporated byreference, strain gauges 304 may be spaced in a ring at intervals aroundthe circumference of the tube 306 mounted on ribs 302 (e.g., 3 gauges at120 degrees, 4 gauges at 90 degrees, or 4 gauges at 70 and 110 degrees).The signals from the sensors are combined arithmetically in various sumsand differences to obtain measures of three perpendicular forces (e.g.,F.sub.x, F.sub.y, and F.sub.z) exerted upon the instrument tip and thetorques about the two axes perpendicular to the shaft axis (i.e., axes xand y). In accordance with the present invention, the measurement of theforces is made independent of the orientation and effective lever armlength of an articulated wrist mechanism at the distal end of theinstrument as well as wrist friction moments and actuator cable tensionswhen two axially separated sets or rings of gauges are utilized. Forcesexerted against end portion 320 are detected by the force sensingelements, which may be operably coupled to the servo control or surgeondisplay means via an interrogator 334 or to a processor 340 fornotifying the surgeon of these forces (e.g., via master(s) or a displaymeans). It is understood that by adding a second ring of similarlyoriented gauges (e.g., two sets of 3 gauges or two sets of 4 gauges) ata different position along the z-axis of the tube, additional appliedtorque information (e.g., T.sub.x and T.sub.y) can be obtained, anddependence of the force data on instrument wrist length, orientation,and resulting jaw distance and cable tensions, can be eliminated.

In one example, various strain gauges may be used, including but notlimited to conventional foil type resistance gauges, semiconductorgauges, optic fiber type gauges using Bragg grating or Fabry-Perottechnology, or others, such as strain sensing surface acoustic wave(SAW) devices. Optic fiber Bragg grating (FBG) gauges may beadvantageous in that two sensing elements may be located along one fiberat a known separation, thereby only requiring the provision of fourfibers along the instrument shaft. Fiber optic gauges may also bedesirable because of their resistance to disturbance from cautery andother electromagnetic noise.

Both fiber technologies require an interrogator unit, such asinterrogator unit 334 (FIG. 5E) that decodes the optically encodedstrain information into electrical signals compatible with the computercontrol hardware of the robotic surgical system. A processor 340 (FIG.5E) operably coupled to the interrogator unit 334 may then be used tocalculate forces according to the signals from the straingauges/sensors.

For resistive foil or semiconductor strain gauges, active componentssuch as bare die op-amps and passive components such as secondaryresistors or capacitors may be attached adjacent to the strain gaugesconnected by bond wires or thick film circuit traces in the manner ofhybrid circuits to amplify, filter, and/or modulate the gauge outputsignals to reject noise sources. Such components are not needed forfiber optic gauges.

In accordance with an embodiment of the present invention, force sensorapparatus 300 is a separately manufactured module or part adapted forincorporation as part of the shaft 310 of a laparoscopic surgicalinstrument at a prescribed distance from the tip where there may be anarticulated wrist with specialized jaws, cutting devices, or other endportion 320. A proximal portion of tube 306 operably couples to theshaft 310 of the surgical instrument and a distal portion of tube 306operably couples to wrist joint 321. In one example, the diameter of thecompleted force sensor apparatus matches the diameter of the instrumentshaft, thus allowing the entire assembly of the instrument (includingthe coupled force sensor apparatus) to pass through a cannula or a sealwithout added friction or snagging. In other embodiments, the surgicalinstrument may be manufactured with a force sensor portion integrated asa part of shaft 310 (i.e., force sensor apparatus 300 is not separablefrom the shaft).

Similar to the embodiments described above, the surgical instrument towhich force sensor apparatus 300 couples may also include a service loop330 (FIG. 5E) of conductive traces or optic fibers at the proximal endof the instrument shaft 310 and a cable swivel mechanism 332 permittingthe substantially free rotation of the instrument shaft while conductingthe input gauge excitation power or light and electrical or opticaloutput gauge signals to the interrogator unit 334.

Similar to the embodiments described above, the housing 150 operablyinterfaces with a robotic manipulator arm, in one embodiment via asterile adaptor interface. Applicable housings, sterile adaptorinterfaces, and manipulator arms are disclosed in U.S. patentapplication Ser. No. 11/314,040 filed on Dec. 20, 2005, and U.S. patentapplication Ser. No. 11/613,800 filed on Dec. 20, 2006, the fulldisclosures of which are incorporated by reference herein for allpurposes. Examples of applicable shafts, end portions, housings, sterileadaptors, and manipulator arms are manufactured by Intuitive Surgical,Inc. of Sunnyvale, Calif.

In a preferred configuration, end portion 320 has a range of motion thatincludes pitch and yaw motion about the x- and y-axes and rotation aboutthe z-axis. These motions as well as actuation of an end effector areprovided via cables, wires, tubes, and/or rods running through throughpassages 308 and into the housing that transfer motion from themanipulator arm. Embodiments of drive assemblies, arms, forearmassemblies, adaptors, and other applicable parts are described forexample in U.S. Pat. Nos. 6,331,181, 6,491,701, and 6,770,081, the fulldisclosures of which are incorporated herein by reference for allpurposes.

It is noted that various surgical instruments may be improved inaccordance with the present invention, including but not limited totools with and without end effectors, such as jaws, scissors, graspers,needle holders, micro-dissectors, staple appliers, tackers, suctionirrigation tools, clip appliers, cutting blades, hooks, sealers, lasers,irrigators, catheters, and suction orifices. Alternatively, the surgicalinstrument may comprise an electrosurgical probe for ablating,resecting, cutting or coagulating tissue. Such surgical instruments aremanufactured by Intuitive Surgical, Inc. of Sunnyvale, Calif.

For the sensing methods and apparatus mentioned above, it may beadvantageous to use a calibration process in which combinations offorces and torques are applied to the instrument tip serially,simultaneously, or in combinations while correction factors and offsetsare determined to apply to the theoretical equations for combining thegauge outputs to obtain F.sub.x, F.sub.y, F.sub.z, T.sub.x, and T.sub.y.This calibration may be done either by directly calculating thecorrection factors and offsets or by a learning system such as a neuralnetwork embedded in the calibration fixture or in the instrument itself.In any calibration method, the calibration data may be programmed intoan integrated circuit embedded in the instrument so that the surgicalsystem using the individual instrument can correctly identify and applyits correction factors and offsets while the instrument is in use.

Advantageously, force sensor apparatus 300 of the present invention isadaptable to the size and shape constraints of robotic endoscopicsurgical instruments and is suitable for a variety of instruments.Furthermore, force sensor apparatus 300 may be manufactured, tested, andcalibrated as a separate modular component and brought together withother components in the conventional instrument assembly process or asan integrated part of the instrument shaft 310. Also, the sensor may bea slip-on module with suitable electrical contacts that mate withcontacts on the instrument shaft permitting a higher value sensor to beused with lower cost instruments of limited cycle life.

The present invention is not limited to rib orientation or a certainnumber of ribs, sets of ribs, strain gauges, or tube apertures, andFIGS. 6A-6C1, 7A-7B1, 8, and 9A-9C illustrate force sensor apparatus inaccordance with other embodiments of the present invention. Thedescriptions of substantially similar parts or elements as thosedescribed above with respect to FIGS. 5A-5E are applicable in theseembodiments although redundant descriptions may be omitted.

Referring now to FIGS. 6A-6C1, a force sensor apparatus 400 isillustrated, the force sensor apparatus 400 including four ribs 402paired at skewed angles (e.g., 70 degrees and 110 degrees) about az-axis centerline of a tube 406. Ribs 402 extend radially within tube406 from the z-axis centerline of the tube providing four throughpassages 408 a and 408 b for passage of actuation cables, wires, tubes,and/or rods. Advantageously, a larger through passage 408 a utilizingskewed angles allows for easier passage of cables, wires, tubes, and/orrods through tube 406 (e.g., three hypodermic tubes may be passed per110 degree channel). In this embodiment, as can be seen in FIG. 6A, tube406 does not include apertures through the wall of tube 406. However,the combined stiffness of tube 406 and ribs 402 still allow for a strongstrain signal to noise signal ratio consistent with a materials choiceand rib design meeting the need for high thermal diffusivity and adirect thermal path between opposing strain gauges while also providingpassage for actuation cables, wires, tubes, and/or rods.

Similar to the embodiments disclosed above, a number of strain gauges404 are oriented parallel to the lengthwise z-axis of the tube andmounted to an outer rib surface 402 a. The strain gauges may be inlaidinto grooves or a depressed area 417 on the outer rib surface 402 a inone example. Wire leads or optic fibers 416 (e.g., shielded twistedpairs, coax, or fiber) coupled to the strain gauges 404 may be inlaidinto grooves 417 on tube 406, the outer rib surface 402 a, and matchinggrooves 417 in a shaft of the surgical instrument. The wire leads oroptic fibers 416 may then be embedded in an adhesive potting compoundsuch as epoxy.

Referring now in particular to FIGS. 6C and 6C1, an end view of forcesensor apparatus 400 and a magnified section labeled 6C 1 in FIG. 6C arerespectively illustrated. A thermal shielding over the strain gauges maybe provided in accordance with another embodiment of the presentinvention. In one example, a thermal shunt shell 452 is provided overtube 406 with an insulating fluid filled gap 450 being provided betweenthe outer surface of tube 406 and the inner surface of thermal shuntshell 452. Thermal shunt shell 452 may be comprised of a highdiffusivity material, such as an aluminum alloy (e.g., 6061-T6 aluminum)or a copper alloy (e.g., GlidCop® AL-60). Optionally, a light reflectivecoating 453 may be provided over thermal shunt shell 452, which maydeflect light and reduce localized heating of the force sensorapparatus. An insulating coating 454 may also be provided over thermalshunt shell 452, the insulating coating 454 being comprised of asubstantially transparent plastic shrink polymer in one example.Advantageously, the thermal shielding over the strain gauges asdescribed above allows for greater heat/thermal diffusion among thesensors, being particularly advantageous for mitigating asymmetricthermal loads upon the instrument. The thermal shielding described aboveis applicable for various embodiments of the present invention.

Referring now to FIGS. 7A thru 7B1, a force sensor apparatus 500 isillustrated, the force sensor apparatus 500 including four ribs 502paired at skewed angles (e.g., 70 degrees and 110 degrees) about az-axis centerline of a tube 506. Ribs 502 extend radially within tube506 from the z-axis centerline of the tube providing four throughpassages 508 a and 508 b for passage of actuation cables, wires, tubes,and/or rods. Advantageously, a larger through passage 508 a utilizingskewed angles allows for easier passage of cables, wires, tubes, and/orrods through tube 506 (e.g., three hypodermic tubes may be passed per110 degree channel). In this embodiment, as can be seen in FIG. 7A, tube506 include apertures 501 provided through the wall of tube 506. Thereduced stiffness of exposed ribs 502 allow for a strong strain signalto noise signal ratio consistent with a materials choice and rib designmeeting the need for high thermal diffusivity and a direct thermal pathbetween opposing strain gauges while also providing passage foractuation cables, wires, tubes, and/or rods.

Similar to the embodiments disclosed above, a number of strain gauges504 are oriented parallel to the lengthwise z-axis of the tube andmounted to an outer rib surface 502 a. The strain gauges may be inlaidinto grooves or a depressed area 517 on the outer rib surface 502 a inone example. Wire leads or optic fibers 516 (e.g., shielded twistedpairs, coax, or fiber) coupled to the strain gauges 504 may be inlaidinto grooves 517 on tube 506, the outer rib surface 502 a, and matchinggrooves 517 in a shaft of the surgical instrument. The wire leads oroptic fibers 516 in grooves 517 may then be embedded in an adhesivepotting compound such as epoxy.

FIG. 8 illustrates a cross-sectional view of another force sensorapparatus which includes three ribs 602 separated by 120 degrees about az-axis centerline of the force sensor apparatus tube 606. Ribs 602provide three through passages 608. Wire leads or optic fibers 616(e.g., shielded twisted pairs, coax, or fiber) coupled to strain gaugesmay be inlaid into grooves 617 on an instrument tube, an outer ribsurface, and matching grooves in a shaft of the surgical instrument.

Referring now to FIGS. 9A-9C, a force sensor apparatus 700 isillustrated, the force sensor apparatus 700 including four ribs 702paired at skewed angles (e.g., 70 degrees and 110 degrees) about az-axis centerline of a tube 706. Ribs 702 extend radially within tube706 from the z-axis centerline of the tube providing through passages708 a and 708 b. In this embodiment, force sensor apparatus 700 alsoincludes a central through passage 708 c along a lengthwise axis of tube706 in accordance with another embodiment of the present invention. Thethrough passages may be used for passage of actuation cables, wires,tubes, rods, and/or fluids. In this embodiment, as can be seen in FIG.9A, tube 706 does not include apertures through the wall of the tube butapertures exposing portions of the interior ribs are within the scope ofthe present invention. Furthermore, the combined stiffness of tube 706and ribs 702 still allow for a strong strain signal to noise signalratio consistent with a materials choice and rib design meeting the needfor high thermal diffusivity and a thermal path between opposing straingauges while also providing passage for actuation cables, wires, tubes,rods, and/or fluids.

Similar to the embodiments disclosed above, a number of strain gauges704 are oriented parallel to the lengthwise z-axis of the tube andmounted to an outer rib surface 702 a. The strain gauges may be inlaidinto grooves or a depressed area 717 on the outer rib surface 702 a inone example. Wire leads or optic fibers 716 (e.g., shielded twistedpairs, coax, or fiber) coupled to the strain gauges 704 may be inlaidinto grooves 717 on tube 706, the outer rib surface 702 a, and matchinggrooves 717 in a shaft of the surgical instrument. The wire leads oroptic fibers 716 may then be embedded in an adhesive potting compoundsuch as epoxy.

Embodiments described above illustrate but do not limit the invention.It should also be understood that numerous modifications and variationsare possible in accordance with the principles of the present invention.For example, the number of strain gauges and their configuration mayvary but must allow for applicable force and torque determinations andnoise rejection. Similarly, the number of ribs and angle between ribsmay vary from those described above. Furthermore, the embodiments offorce sensor apparatus described above may be integrated with a surgicalinstrument upon manufacture as a non-separable part of the shaft.Accordingly, the scope of the invention is defined only by the followingclaims.

The invention claimed is:
 1. A force sensor apparatus comprising: a tubeportion including an outer surface and a lengthwise axis, the tubeportion being a shaft of a surgical instrument, and the outer surfaceextending in a direction of the lengthwise axis, the shaft of thesurgical instrument extending between a housing of the surgicalinstrument and a joint of the surgical instrument; a plurality of radialribs, the plurality of radial ribs being inside the tube portion, eachradial rib of the plurality of radial ribs extending lengthwise in thedirection of the lengthwise axis, and each radial rib of the pluralityof radial ribs extending radially along a radius of the tube portion tothe tube portion, a first surface of a first radial rib in the pluralityof radial ribs, a second surface of a second radial rib in the pluralityof radial ribs, and a portion of inner surface of the tube portionbounding a through-passage within the tube portion; a plurality ofstrain gauges, each strain gauge in the plurality of strain gauges beingat the outer surface, each strain gauge in the plurality of straingauges being positioned and aligned lengthwise with a correspondingradial rib of the plurality of radial ribs; and a cable extending fromthe housing through the through-passage to the joint.
 2. The apparatusof claim 1, wherein the plurality of radial ribs are comprised of amaterial selected from a group consisting of metal alloys, treatedmetals, and plated metals.
 3. The apparatus of claim 1, wherein theplurality of radial ribs includes one plurality selected from the groupconsisting of four ribs spaced apart by about 90 degrees about thelengthwise axis of the tube portion and three ribs spaced apart by about120 degrees about the lengthwise axis of the tube portion.
 4. Theapparatus of claim 1, wherein the plurality of radial ribs includes tworibs spaced apart by 110 degrees about the lengthwise axis of the tubeportion and two ribs spaced apart by 70 degrees about the lengthwiseaxis of the tube portion.
 5. The apparatus of claim 1, wherein eachstrain gauge of the plurality of strain gauges is aligned with one otherstrain gauge of the plurality of strain gauges along an axis parallel tothe lengthwise axis of the tube portion.
 6. The apparatus of claim 1,wherein a primary strain sensing direction of each of the plurality ofstrain gauges is oriented parallel to the lengthwise axis of the tubeportion.
 7. The apparatus of claim 1, wherein the plurality of straingauges is selected from the group consisting of a Fabry-Perot straingauge and a fiber Bragg grating strain gauge.
 8. The apparatus of claim1, wherein the plurality of strain gauges are positioned in a pluralityof grooves in the outer surface.
 9. The apparatus of claim 1, furthercomprising at least one aperture on the outer surface of the tubeportion, wherein the aperture is spaced between individual stain gaugesin the plurality of strain gauges, and wherein the aperture exposes atleast one of the plurality of radial ribs.
 10. The apparatus of claim 1,further comprising a thermal shunt shell over the outer surface of thetube portion, and a fluid filled gap between an inner surface of thethermal shunt shell and the outer surface of the tube portion.
 11. Theapparatus of claim 10, further comprising an insulating material overthe thermal shunt shell.
 12. The apparatus of claim 10, furthercomprising a light reflective coating over the thermal shunt shell. 13.The apparatus of claim 1, further comprising a central through passagealong a lengthwise axis of the tube portion.
 14. A force sensorapparatus comprising: a first tube portion including an outer surfaceand a lengthwise axis, the first tube portion being a shaft of asurgical instrument, and the outer surface extending in a direction ofthe lengthwise axis, the shaft of the surgical instrument extendingbetween a housing of the surgical instrument and a joint of the surgicalinstrument; a second tube portion, the second tube portion beingpositioned inside the first tube portion; a plurality of ribs, theplurality of ribs being inside the first tube portion and outside thesecond tube portion, each of the plurality of ribs extending radiallyalong a radius of the first tube portion and extending from the secondtube portion to the first tube portion, and each rib of the plurality ofribs extending lengthwise in the direction of the lengthwise axis, afirst surface of a first radial rib in the plurality of ribs, a secondsurface of a second radial rib in the plurality of ribs, a portion ofinner surface of the first tube portion, and a portion of an outersurface of the second tube portion bounding a through-passage within thefirst tube portion; a plurality of strain gauges, each strain gauge inthe plurality of strain gauges being at the outer surface of the firsttube portion, each strain gauge in the plurality of strain gauges beingpositioned and aligned lengthwise with a corresponding rib of theplurality of ribs; and a cable extending from the housing through thethrough-passage to the joint.
 15. The apparatus of claim 14, wherein theplurality of ribs are comprised of a material selected from a groupconsisting of metal alloys, treated metals, and plated metals.
 16. Theforce sensor apparatus of claim 14, wherein the plurality of ribsincludes two ribs spaced apart by 110 degrees about the lengthwise axisof the first tube portion and two ribs spaced apart by 70 degrees aboutthe lengthwise axis of the first tube portion.
 17. The apparatus ofclaim 14, wherein each strain gauge of the plurality of strain gauges isaligned with one other strain gauge of the plurality of strain gaugesalong an axis parallel to the lengthwise axis of the first tube portion.18. The apparatus of claim 14, further comprising a shell positionedover the outer surface of the first tube portion to form a gap betweenan inner surface of the shell and the outer surface of the first tubeportion.
 19. The apparatus of claim 14, further comprising at least oneaperture on the outer surface of the first tube portion, wherein theaperture is spaced between individual stain gauges in the plurality ofstrain gauges, and wherein the aperture exposes at least one of theplurality of ribs.